Finger wedge foam

ABSTRACT

A flexible foam wedge, designed with a finger pocket and application tip with that allows for direct support of the applicator from a finger digit particularly useful for the application of cosmetics. The foam applicator comprises a base block defining the finger opening. The application tip, having any of a plurality of configurations extends from the base block. The applicator can be an integral unit, or can comprise separate components connected together. Further, various methods of manufacturing and using the applicator are provided.

[0001] This application is based on and claims priority in U.S.Provisional Patent Application Serial No. 60/225,223 filed 14 Aug. 2000.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to foam applicators for use on afinger or other digit. The foam applicators are particularly useful forthe application of cosmetics.

[0004] 2. Description of the Related Art

[0005] In the past, cosmetic applicators have taken a variety of shapessuch as pads, rounds, puffs, swabs, etc. as a means for applying variouscosmetic products. Direct hand application of cosmetic products isundesirable, since the fingers do not optimally retain or apply thecosmetic product. The use of swabs is common as it provides an extensionfor an applicator, although by nature it is a less direct method ofcosmetic product application. Such a swab applicator is shown in WO99/58017. Furthermore, applicators of the past have often beencomplicated or uneconomical for efficient use.

SUMMARY OF THE INVENTION

[0006] According to the present invention, there is provided anapplicator comprising a base block. The base block defines a bottomsurface. At least one side wall extends from the bottom surface. Theapplicator further comprises a foam application tip extending from thebase block. The applicator further includes a finger opening extendingfrom the bottom surface between the side wall. The finger opening issized to receive at least a portion of a user's finger.

[0007] Also provided are methods for forming the applicator. One suchpresently preferred method comprises forming a first sheet of foammaterial to define a blank. At least one applicator is formed from theblank such that each applicator defines a base block and an applicationtip extending from the base block. A finger opening is formed in thebase block.

[0008] Another such presently preferred method comprises providing amold defining a cavity therein. Foam is injected into the cavity andallowed to cure to define a blank. The blank is then removed from themold. The shape of at least one applicator comprising a base block andan application tip is cut in the blank. At least one opening is cutthrough said base block. Finally, a finger opening is cut in the baseblock transverse to the opening.

[0009] An alternate presently preferred method for forming theapplicator comprises providing a mold defining a cavity therein. Aplurality of finger pins are provided in the cavity. Foam material isinjected into the cavity and about the finger pins and allowed to reactto define a blank having a plurality of finger openings. The finger pinsare removed from the cavity, and the blank is removed from the mold. Theshape of at least one applicator comprising a base block and anapplication tip is cut in the blank about the finger openings.

[0010] Yet another presently preferred method of forming the applicatorcomprises forming a first sheet. A plurality of finger openings areformed in the first sheet. A second foam sheet having a plurality ofapplication tips formed or cut thereon is obtained. The first sheet isadhered to the second foam sheet. The applicators are cut from thecombined first sheet and second foam sheet such that each applicatordefines a base block with the finger opening and an application tipextending from the base block.

[0011] Yet another presently preferred method of forming the applicatorscomprises forming a blank of foam material. A plurality of through holesare formed into the foam block. Further, the foam block is cut toprovide the shape of individual applicators. Subsequently, fingeropenings are cut through the foam and connected to the through holes.

[0012] A method for using the applicator is also provided. The presentlypreferred method comprises obtaining an applicator having a base blockwith a finger opening and a foam application tip. The base block isplaced on a user's finger. The application tip is placed in a materialto be applied, and the material is applied to a surface.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Presently preferred embodiments of the invention are disclosed inthe following detailed description and in the accompanying drawingswherein:

[0014]FIGS. 1a-1 f are elevational views showing some sample shapes forthe application tip and finger opening;

[0015]FIG. 2 is a top plan view showing a sample block design to makethe various applicators;

[0016]FIG. 3 is a perspective view of an alternate embodiment of anapplicator;

[0017]FIG. 4 is a perspective view of an alternate embodiment of anapplicator;

[0018]FIGS. 5a-5 b is a top plan view of a block design showing variousalternative tip configurations;

[0019]FIG. 6a shows a side view of a mold for molding a blank;

[0020]FIG. 6b is an end view of a mold for molding a blank;

[0021]FIG. 6c is a top view of a mold for molding a blank;

[0022]FIG. 6d is a plan view of a mold insert for molding the fingercavity;

[0023]FIG. 6e is a perspective view of a finger wedge having beenremoved from the block and showing the cut lines;

[0024]FIG. 6f is a perspective view of an applicator in accordance withone preferred embodiment of the present invention;

[0025]FIG. 7a shows a foam block having a finger opening;

[0026]FIG. 7b shows a perspective view of one preferred applicator;

[0027]FIG. 7c is a perspective view of an applicator on a user's finger;

[0028]FIG. 7d is a top plan view of a mold for making a foam blank, andshowing sample cut lines for making a plurality of applicators;

[0029]FIG. 7e is a perspective view of a foam blank and showing thelines for cutting the respective applicators;

[0030]FIG. 8 shows multiple plan views of various applicators that canbe formed from a blank;

[0031]FIG. 9 shows one presently preferred mold for making applicators;

[0032]FIGS. 10a-10 g represent an alternate method of forming anapplicator;

[0033]FIG. 11 is a schematic representation of another presentlypreferred method of making the present applicators;

[0034]FIG. 12 is an end view of an alternate embodiment of an applicatorshowing the use of a band to secure the applicator on the user's finger;

[0035]FIG. 13 shows another alternative embodiment of an applicatorshowing a hook and loop fastener to support the applicator on a user'sfinger;

[0036]FIG. 14 is a top plan view of a blank for producing variousapplicator tips;

[0037]FIG. 15 is a top plan view of an alternate blank design showing ablank for producing various applicators; and

[0038]FIG. 16 is a side view of a pair of applicators on a user'sfinger.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] An applicator is generally shown at 10 in the figures. Theapplicator includes a base block generally indicated at 12. In onepreferred embodiment, the base block 12 comprises a bottom surface 14and four side walls 16 extending upwardly from the bottom surface 14. Afinger opening 18 is also included. The finger opening 18 extendsupwardly from the bottom surface 14 interiorly of the side walls 16. Thefinger opening 18 is sized to receive at least a portion of the user'sfinger. It will be appreciated that while the preferred embodiment isfor use on a user's finger, that in certain instances, the device may beused on other digits, such as, for example, a user's toes.

[0040] In one preferred embodiment as best seen in FIGS. 6e and 7 b, thebase block 12 has a generally square or rectangular cross-section. Itwill be appreciated, however, that any number of side walls including asingle side wall having a circular cross-section as shown, for example,in FIG. 3, may be used. The area between the side wall 16 is filled andthat area as well as the side walls themselves preferably comprise foam.

[0041] The base material for the cellular foam is a polymeric materialsuch as a foamed organic plastic. The air pockets, which comprise of thecells, can be open or closed. Exemplary of acceptable polymers employedin the foaming industry are polyurethane, ethylene/vinyl acetate (EVA)copolymer, latex, polyethylene, polypropylene, butyl, silicone,cellulose acetate, neoprene, epoxy, polystyrene, phenolic, polyvinylchloride (PVC), and other related polymers.

[0042] In designing the base for the cellular foam, the base polymer,prepolymer (liquid or solution), or reactants and fabrication areaccomplished according to conventional or non-conventional foamingtechniques. During fabrication, selecting a liquid polymer and/orelastomer/reactant, and then causing the foregoing to be foamed formsthe cellular foam. Common methods of foaming include adding a hardeningagent, which causes a chemical reaction, thermally setting the basematerial with heat, or bubbling a gas through the liquidpolymer/elastomer while hardening, or other methods well known to thoseskilled in the art.

[0043] The applicator 10 further includes a foam application tip 20. Thefoam application tip 20 extends from the base block 12. The foam usedfor the application tip 20 is the same as that set forth above.

[0044] Some basic design styles are shown in FIGS. 1a-1 f. These shapesrepresent some possible shape combinations of the finger openings 18with various application tip 20 shapes. It will be appreciated that theapplication tip 20 is preferably contoured and can take anyconfiguration depending upon the final use of the applicator 10. Thefinger opening 18 within the interior of the base block 12 allows fingerinsertion thus defining a finger cot or pocket. This finger opening 18allows for a relatively more controlled application of material to beapplied due to the fact the foam application tip 20 is controlleddirectly by a user's finger inserted into the opening 18. The variousshaped tips 20 allow for different uses. For example, rounded shapesallow for large area spreading, while the pointed tips can be used forpoint specific blotting, applying, etc.

[0045] It will be appreciated that the applicator 10 is particularlyuseful as a cosmetic applicator. The applicator 10 allows for thephysical application by a generally wedge shaped foam object, directlymounted to a finger or other digit. While the applicator 10 isparticularly useful for applying cosmetics, the intended use of theapplicator 10 can be any imaginable use. Some other uses for thepresently preferred applicator are in connection with application ofpaints, sunscreens, lotions, baby products, etc. Further, the applicatorcan be used as a cleaning aid used to wipe various components. Otherapplications may include use as a chalkboard or dry board eraser whenminor changes are required to be made in something written on achalkboard or dry board.

[0046] It is preferred that several applicators 10 are formed togetherfrom a large sheet or a blank and cut to the specific configurationdesired. FIG. 2 shows an example of a formed sheet or blank generallyindicated at 22 used to make several applicators 10. The blank 22 designof FIG. 2 allows for the efficient, simultaneous production of severalapplicators 10, especially as a variety of shapes for the tip 20 can becut such as by die cutting from a single blank 22, eliminating orreducing waste inherent with unusual shapes.

[0047] It will be appreciated that the blank 22 can be formed in anymanner. For example, the blank 22 can be formed by casting the foam intoopen blocks or into continuous sheets or rolls. Alternatively, the blank22 can be made by reaction injection molding the blank 22. These methodsare well known in the art. If large sheets are formed, they willconstitute the blank 22 and may either be cut first into smaller foamblanks from which the individual applicators may be formed, oralternatively, the cutting operation of the blank 22 may simultaneouslyform a plurality of applicators 10. In this case, a large sheet or evenrolled sheet comprises the blank 22, may be fed into a die cutter, whichcuts the individual applicators 10, preferably in a continuous manner.

[0048] When the applicators 10 are made from a blank 22, the base block12 and foam application tip 20 are formed as a single piece. That is,once the applicator is formed, such as by die cutting from the blank 22,it is a single, unitary foam material including both the base block 12and foam application tip 20. Further, the finger openings 18 may besimultaneously molded onto the blank 22. Alternatively, the fingeropenings 18 may be cut, or otherwise formed into the base blank 22 ordirectly into individual applicators 10.

[0049]FIG. 3 shows an alternate preferred embodiment having a two-partdesign that allows for replaceable tips 20. The assembly includes a baseblock 12′ that defines a singular side wall 16 extending from a bottomsurface 14. Specifically, a sock or sleeve 24 of elastic, foam or othersuitable material is provided. The sleeve 24 includes the finger opening18 forming a pocket for a finger. A connector, generally indicated at26, is also provided. The connector 26 shown preferably comprises amounting base 28 connected with the base block 12′. A post 30 extendsfrom the mounting base 28 in a direction away from the sleeve 24. Thepost 30 has a ball tip 32 thereon.

[0050] A separate foam tip 20′ is adapted for connection with theconnector 26. As shown, the foam tip 20′ includes an engaging surface 33and a receiving opening 34 extended from the engaging surface 33 forreceiving the post 30. To connect the foam tip 20′ with the base block12, the foam tip 20′ is placed over the connector 26. The base block 22and foam tip 20′ are pushed closer until the post 30 is disposed withinthe receiving opening 34. Preferably, the diameter of the ball tip 32 isslightly larger than the diameter of the receiving opening 34. In thismanner, the ball tip 32 will engage the receiving opening 34 and retainthe foam tip 20′ on the connector 26.

[0051] While the connector 26 is preferably shown to comprise a mountingbase 28 having a post 30 thereon, the connector 26 could also be a flatsurface for receiving Velcro, adhesive, tape, snaps or the like. Anysuitable connector 26 may be used. Similarly, the foam tip 20′ mayinclude Velcro, adhesive, tape, snaps or the like to connect it with theconnector 26 on the sock 24. Again, any method of securing the tip 20′with the sleeve 24 is contemplated. Preferably, a detachable method isused so the sleeve 24 can be used with several tips 20′. This methodoffers the ability to connect a wide variety of tip 20′ designs to asingle base block 12.

[0052] In another preferred embodiment as shown in FIG. 4, an alternatetwo-part design as described above is used. The base block 12 has fourside walls 16 extending from a bottom surface 14. Also provided is a topsurface 36. Thus, the base block 12 comprises a block having a generallysquare or rectangular cross-section. A finger opening 18 extendsinwardly of the side wall 16 from the bottom surface 14.

[0053] An application tip 20′ is also included. The application tip 20′comprises a foam, as set forth above and has an engaging surface 33. Theapplication tip 20′ may be secured to the top surface 36 of a block 12utilizing any method, such as, for example, the use of Velcro, adhesive,tape, snaps, or the like.

[0054] The use of the design of FIG. 4 also allows for the use of a baseblock 12 having a color different from the color of the application tip20′. By the use of a different color tip 20′ from the base block 12, auser can more readily distinguish the replaceable tip 20′ section fromthe base block 12.

[0055]FIG. 5 shows another blank 22′ depicting some possible tip 20′varieties that can be used according to the type of application desired.These tips 20′ are shown within the construction of a master blank 22′,to illustrate the efficiency of cutting various patterns for minimalbase foam waste. While not specifically shown, a receiving opening canbe cut in the tip 20′ to engage a receiving post 30 as described above.Again, the blank 22′ may be produced in any manner.

[0056]FIGS. 6a-6 c show a mold construction in accordance with onepresently preferred method. As shown, the side view of FIG. 6a includesa mold generally indicated at 38. The mold 38 includes a bottom surroundgenerally indicated at 40. The mold 38 also includes a top 42.Preferably, the top 42 and bottom surround 40 of the mold 38 are made ofmetal. When the top 42 is placed on the bottom 40, a mold cavity 46 isdefined between the walls 44 of the bottom surround 40 and the top 42.The cavity 46 can comprise any configuration to make either individualapplicators 10 or a blank 22 from which multiple applicators can bemade. As shown, the mold 38 will make a blank 22 having a plurality offinger openings 18 molded therein.

[0057] A plurality of tapered finger pins 48 extend downwardly from atop 42 of the mold 38. The finger pins 48 are preferably covered with anon-stick surface, such as, for example, with Teflon tape, and extendinto the mold cavity 46. As best shown in FIG. 6b, the finger pin 48 mayinclude a threaded connection portion 50 for attaching the finger pin 48to the top 42. More specifically, the top 42 may include threadedopenings for receiving the threaded connector portion 50 of the pin 48.In this manner, the pins 48 can be releasably secured into the top 42.It will be appreciated, however, that the finger pins 48 may bepermanently secured to the mold 38 in any suitable manner.

[0058] Alignment pins 52 are used to align the top 42 with the bottomsurround 40 of the mold 38. The alignment pins 52 can be located at anylocation between the top 42 and bottom surround 40. Further, the pinscan be used merely to align and locate the top 42 on the bottom surround40. In such a case, a suitable clamp, not shown in FIGS. 6a-6 c, may beused to secure the top 42 to the bottom surround 40 during the moldingoperation. Alternatively, the pins 52 may be configured to secure thetop 42 with the bottom surround. For example, the pins 52 may bethreaded and extend all the way through the top 42 and into a threadedopening in the walls 44 of the bottom surround 40. It will beappreciated that at least one of the top 42 and bottom surround 40 ofthe mold 38 also includes a port for allowing the foam material to beinjected into the mold cavity 46.

[0059] When a mold of the type shown in FIGS. 6a-6 c is used, a masterfoam blank 22 containing a plurality, four as shown, of individualapplicators is produced. The master blank 22 is a block having agenerally rectangular cross-section with four finger openings 18integrally molded therein. The master blank 22 formed is then cut intothe individual applicators such as shown in FIGS. 6e-6 f. As shown inFIG. 6e, a square finger wedge is formed which finger wedge is cut fromthe foam block 22 produced in the mold cavity 58. The square fingerwedge includes the side walls 16, bottom surface 14 and finger openings18. The tip 20 is not yet cut. FIG. 6e shows the line along which theapplication tip 20 may be cut. Finally, the finger wedge is cut toproduce a tip 20 having its desired final shape also shown in FIG. 6f.It will be appreciated that the tip 20 may take any configuration.

[0060]FIG. 7d shows an alternate mold cavity 46′ arrangement. The mold38′ includes a central branch 54. The finger pins 48′ are shownextending from a central branch 54. By utilizing a mold 38′ in thismanner, two mold cavity segments 46′ are produced. Each mold cavitysegment 46′ produces a master foam blank 22 (FIG. 7e), which can be cutinto several applicators, FIGS. 7a-7 b. As shown, applicators withpointed tips 20 are produced.

[0061]FIG. 7d further shows the lines where the applicators may be cut.Similarly, FIG. 7e depicting the master blank 22 having the fingeropenings 18 molded therein also shows the lines along which theindividual applicators may be cut. FIG. 7a shows the finger wedge formedafter the first cut is made separating the individual applicators. FIG.7b shows the final applicator 10 after the tip 20 having the desiredconfiguration has been cut into the finger wedge shown in FIG. 7a. Itwill be appreciated that the cutting of the foam wedge and applicationtip 20 may be done simultaneously.

[0062]FIG. 7c shows the applicator 10 with the user's finger insertedinto the finger opening 18. It will be appreciated that the fingeropening 18 will take a configuration suitable to accept the user'sfinger. Because the finger opening 18 is surrounded either by a foam oran elastic material, it readily adapts to the shape of the user'sfinger.

[0063] Again, it will be appreciated that the finger openings may bemolded into the blank 22. Alternatively, the finger pins 48′ may beexcluded from the mold and in such a case, the finger openings will beformed in the applicator in accordance with any acceptable method.

[0064]FIG. 8 shows several individual wedges with some potential shapesfor the various application tips 20 that may be used. Specifically, FIG.8 depicts the lines along which the individual application tips 20 maybe cut to form an applicator. The configuration of each of theapplicators depicted is identical except for the configuration of thetip 20. Obviously, it is understood that the application tips 20 cantake any configuration and are not limited to those shown in FIG. 8.

[0065]FIG. 9 shows a cross-sectional view of the mold of FIG. 7d. Again,two mold cavity segments 46′ are produced when utilizing a design ofthis nature. The finger pins 48 are threaded into the main branch 55. Atop 42 is secured to the bottom 40 having a plurality of walls 44 of themold 36 and is aligned by a plurality of locator or alignment pills 52.Clamps 56 are used to secure the top 42 to the bottom 40. Once the top42 is secured to the bottom 40, foam is injected through a suitable portinto the cavity segments 46′ and the foaming reaction takes place. Uponcompletion of the foaming operation, the top 42 is removed and theformed foam blanks 22 are removed from each mold cavity segment 46′. Thefoam blanks 22 can then be formed into any desired configuration.

[0066]FIG. 10 shows a schematic for an alternate preferred method formaking an applicator 10. Originally, an applicator 10 having a fingeropening 18 is formed in accordance with any method. The base block 12 isthen thermoformed by application of heat and pressure. The thermoformingprocess takes place by heated pressing of a foam shape around a formingtool. The thermoforming process results in a solid, stretchy,rubber-like material in the areas thermoformed. As shown in FIG. 10b, aheated welding tool 92 is used. Also, a round forming tool 94 isinserted into the finger opening 18. Once the round forming tool 94 isinserted in the finger opening 18, the heated welding tool 92 is closed,applying pressure to the base block 12, FIGS. 10c-10 e. Upon completionof the thermoforming process, the base block 12′ is shown to include asingular side wall 16′ that is a solid, stretchy, rubber-like materialthat can be stretched over a user's finger, FIG. 10g. The finger opening18 then can stretch to fit any size finger.

[0067]FIGS. 11a-11 e is a schematic representation of an alternatepreferred method of forming the applicators. FIG. 11a shows a foam blockor sheet 70 having a plurality of finger openings 18 therein. The foamblock 70 can be obtained by utilizing any suitable process, such asreaction injection molding or casting the foam material. The fingeropenings 18 can be formed in the block 70 either during a moldingoperation or can subsequently be formed in the block 70.

[0068]FIG. 11b depicts a second block of foam material 72. Preferably,the second block 72 has the tip configurations extending in oppositedirections from a central portion 74. The tip configurations 20′ cantake any shape. It will be appreciated that the second block 72 isformed in any manner, such as for example as that set forth for thefirst block 70. It will be appreciated that the second block can beformed having the tip configurations extending in only one direction.That is, the second block can be formed to directly provide the sheet asshown in FIG. 1d.

[0069]FIG. 11c depicts the next step of separating the second block 72into two separate sheets 76 each having the application tips 20′thereon. Each of the sheets 76 defines a generally flat base surface 78.As shown in FIG. 11d, a suitable adhesive may then be applied to thebase surface 78. The foam block 70 is then placed on top of the basesurface 78 having the adhesive thereon. In this manner, the foam block70 having one generally flat surface is secured with the sheet 76. Oncethe adhesive has secured the foam block 70 with the sheet 76, each ofthe individual applicators 10 may then be cut from the connectedseparate sheets 76 and foam block 70.

[0070]FIGS. 12a and 12 b depict another preferred embodiment of anapplicator 10. As shown, the applicator 10 comprises a base block 12′having a bottom surface 14′ and side walls 16′. A finger opening 18′ isalso included. A foam application tip 20 extends from the base block12′. As shown, the tip 20 is integral with the base block 12′. It willbe appreciated, however, that the base block 12′ and tip 20 may compriseseparate components connected together in a manner set forth above. Asshown in FIGS. 12a and 12 b, the finger opening 18′ extends through twoof the side walls 16′, thus creating a slot therebetween. A band 80,such as a band of elastic material, may be placed about the exterior ofthe side walls 16′ to help secure the base block 12′ on a user's finger.This is best seen in FIG. 12a. Further, the side walls 16′ may include adepression 82, best seen in FIG. 12b, for receiving the band 80.

[0071] It will be appreciated that while the finger opening 18′ is shownto extend through two side walls 16′ of the base 12′, the finger opening18′ may comprise merely an opening between the side walls 16′ as is setforth with the embodiments above. Of course it will be appreciated thatthe application tip 20 may take any configuration, depending on thedesired application.

[0072]FIGS. 13a and 13 c-13 f further depict the alternate preferredembodiment of FIGS. 12a and 12 b, but show a different type of band 80′.As shown, the band 80′ preferably comprises a hook and loop type strap,commonly known as Velcro. The Velcro strip 80′ includes a hook portion84 and a loop portion 86. The band 80′ is wrapped around the base block12′ and secured in the usual manner. Other than with respect to the useof a hook and loop band 80′, the configuration of the applicator 10shown in FIGS. 13a-13 f is the same as that described with respect toFIGS. 12a and 12 b. FIGS. 13a, 13 d, 13 e, and 13 f also show variousshapes for the application tip 20.

[0073]FIG. 14 is a top plan view of an alternate blank 88 used to make aplurality of applicators 10. The blank 88 may formed from a sheet in themanner as set forth above in connection with the blank 22. Again, itwill be appreciated that the blank 88 may comprise a large sheet orrolled good, as set forth above. The blank 88 as shown in FIG. 14further shows the lines for a plurality of cutting operations.Specifically, once the blank 88 is formed, a plurality of openings,preferably through holes 90 are cut through side walls 16″ to form thethrough hole 90 through the entirety of the block 88. It will beappreciated that while the through hole 90 preferably passes throughopposite side walls 16, the through hole may pass only through one sidewall 16″. In one preferred method, at the same time the through holes 90are cut into the blank 88, the configuration of the individualapplicators, including the application tips 20, is simultaneously cut.In the most preferred embodiment, the individual applicators are cutsuch that they remain connected by a perforation segment along the linesof the adjacent applicators. Thus, the blank 88 remains integral buteach of the individual applicators can be separated from each other anywaste material simply by tearing across the remaining perforations.

[0074] After the through hole 90 and the cutting of the applicators havebeen completed, the blank 88 can have the finger openings 18 cuttherein. By making the through holes 90, the finger openings 18 can bereadily cut from the bottom surface 14 through the interior of the sidewalls 16″ and to the through hole 90. More specifically, the blank 88with the through holes 90 can have a pin or other support structure (notshown) inserted into the through hole 90 to provide a support forcutting the finger opening 18. This method eliminates the need tosimultaneously mold in the finger openings 18 and rather allows thefinger openings to be cut into the base block 12″.

[0075] Once each of these operations have been completed, the individualapplicators 10 may be separated from each other and any waste materialsimply by pulling on the applicator and separating it along theperforation lines that have been cut. In addition to providing aplurality of applicators 10, the block may simultaneously produce aplurality of tips 20′ for use in a two-part system may also be included.As shown, the tips 20′ can have the receiving opening 34 molded orotherwise cut therein. It will be appreciated that the area betweenadjacent applicators may comprise an alternate tip 20′ or may simply bescrap, discarded material.

[0076]FIG. 16 shows the individual applicator 10 made from the foamblank 88 shown in FIG. 14 in use. The individual applicator 10 isidentical to that depicted above with respect to FIGS. 1, 6f, and 7 c,except that the through hole 90 passes through two side walls 16″. Itwill further be appreciated that a band 80′ may be placed about theexterior of the side walls 16″ to help secure the applicator 10 to theuser's finger.

[0077]FIG. 15 depicts an alternate blank 88′ that can be used to makethe individual applicators 10 as shown in FIG. 16. The blank 88′ has adifferent exterior configuration than the blank 88 shown in the FIG. 14.Otherwise, the manner of manufacturing the applicators 10 is the same asthat described above.

[0078] While the finger holes are shown to be formed either byintegrally molding them or die cutting them, the holes can be formed inany manner. In addition to molding or die cutting the holes, the holesmay be ground into the applicator 10, punched, hot-wire cut, orthermoforming. It will be appreciated that the finger holes can meformed in any manner, including any of the aforesaid methods of formingthe finger holes. Similarly, any of the forming operations describedabove to form the applicators 10 may also utilize any conventionalmethod, such as die cutting, drilling, grinding, molding, punching orhot-wire cutting.

[0079] The invention has been described in an illustrative manner as tobe understood that the terminology which has been used is intended to bein the nature of words of description rather than of limitation. Thedisclosed embodiments are representative of presently preferred forms ofthe invention, but are not intended to be limiting. The invention isdefined in the claims.

What is claimed is:
 1. An applicator comprising: a base block defining abottom surface and at least one side wall extending from said bottomsurface; a foam application tip extending from said base block; and afinger opening extending from said bottom surface between said sidewall, said finger opening sized to receive at least a portion of auser's finger.
 2. An applicator as set forth in claim 1 wherein saidbase block comprises foam.
 3. An applicator as set forth in claim 2wherein said foam of said base block and said application tip iscellular.
 4. An applicator as set forth in claim 2 wherein said baseblock and said foam application tip are formed as a single piece.
 5. Anapplicator as set forth in claim 2 wherein said base block and said foamapplication tip are formed separately and secured together.
 6. Anapplicator as set forth in claim 2 wherein said base block defines fourside walls.
 7. An applicator as set forth in claim 6 wherein said baseblock includes an opening extending through at least one of said sidewalls and being connected to said finger opening.
 8. An applicator asset forth in claim 1 wherein said base block comprises a sleeve having aconnector extending therefrom.
 9. An applicator as set forth in claim 8wherein said foam application tip includes a receiving opening adaptedto receive said connector to thereby connect said application tip withsaid sleeve.
 10. An applicator as set forth in claim 8 wherein saidconnector comprises a base, and a post extending from said base, saidpost adapted for disposition in said receiving opening.
 11. Anapplicator as set forth in claim 10 wherein said post includes a tipthereon, said tip having a larger diameter than said post.
 12. Anapplicator as set forth in claim 10 wherein said sleeve compriseselastic, and said base and said post comprise plastic.
 13. An applicatoras set forth in claim 2 wherein said applicator further includes a bandadapted for disposition about said base block.
 14. An applicator as setforth in claim 13 wherein said band is elastic.
 15. An applicator as setforth in claim 13 wherein said band includes a hook and loop portion.16. A method of forming foam applicators comprising: forming a foamsheet to define a blank forming the shape of at least one applicatorcomprising a base block and an application tip in the blank; forming atleast one opening through said base block; and forming a finger openingis said base block transverse to the opening.
 17. A method as set forthin claim 16 further comprising forming the finger opening to connectwith the opening.
 18. A method as set forth in claim 17 furthercomprising cutting the shape of the applicators by die cutting the shapesuch that adjacent of said applicators remain attached by a relativelysmall amount of foam material.
 19. A method as set forth in claim 18further comprising separating adjacent applicators by applying a manualforce.
 20. A method as set forth in claim 17 further comprising cuttingthe shape of the applicators by die cutting the shape to produce aplurality of individual applicators.
 21. A method of forming foamapplicators comprising: providing a mold defining a cavity therein;providing a plurality of finger pins in said cavity; injecting a foaminto the cavity and about said finger pins and reaction injectionmolding the foam material to define a blank having a plurality of fingeropenings; removing the finger pins from the cavity; removing the blankfrom the mold; cutting the shape of at least one applicator comprising abase block and an application tip in the blank, about the fingeropenings.
 22. A method as set forth in claim 21 further comprisingcoating the finger pins with a non-stick material.
 23. A method offorming foam applicators comprising: forming a first sheet; forming aplurality of finger openings in said first sheet; forming a second foamsheet having a plurality of application tips formed thereon; adheringthe first sheet with the second foam sheet; forming the applicators fromthe combined first sheet and second foam sheet such that each applicatordefines a base block with the finger opening and an application tipextending from the base block.
 24. A method as set forth in claim 23wherein the first sheet is foam.
 25. A method as set forth in claim 23wherein the second foam sheet is made by forming a foam block havingapplication tips extending from two sides, and separating the foam blockinto two second foam sheets each including a plurality of applicationtips.
 26. A method as set forth in claim 23 wherein said first and saidsecond sheets each include a generally flat surface.
 27. A method ofusing an applicator comprising: obtaining an applicator having a baseblock with a finger opening and a foam application tip; placing the baseblock on a user's finger; placing the application tip in a material tobe applied; and applying the material to a surface.
 28. A method offorming foam applicators comprising: providing an applicator having anapplication tip and a base block wherein each of said of application tipand said base block comprise foam; applying pressure and heat to thebase block to define a base block having a finger opening for receivinga user's finger.
 29. A method of forming foam applicators comprising:forming a first sheet of foam material to define a blank; forming atleast one applicator from the blank such that each applicator defines abase block and an application tip extending from the base block; forminga finger opening in the base block.
 30. A method as set forth in claim29 further comprising forming an opening in said base block transverseto the finger opening.
 31. A method as set forth in claim 30 furthercomprising forming the finger opening to connect with the opening.
 32. Amethod as set forth in claim 29 further comprising cutting the shape ofthe applicators by die cutting the shape such that adjacent of saidapplicators remain attached by a relatively small amount of foammaterial.
 33. A method as set forth in claim 32 further comprisingseparating adjacent applicators by applying a manual force.
 34. A methodas set forth in claim 29 further comprising cutting the shape of theapplicators by die cutting the shape to produce a plurality ofindividual applicators.
 35. A method as set forth in claim 29 whereinsaid sheet is formed by casting foam material.
 36. A method as set forthin claim 35 wherein each applicator is formed by die cutting theapplicator.
 37. A method as set forth in claim 36 wherein the fingeropening is formed by die cutting.
 38. A method as set forth in claim 29wherein said sheet is formed by reaction injection molding foammaterial.
 39. A method as set forth in claim 38 wherein each applicatoris formed by die cutting the applicator.
 40. A method as set forth inclaim 39 wherein the finger opening is formed by die cutting.
 41. Amethod as set forth in claim 40 wherein the finger opening is formed bymolding.